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By D. A. Norrgran, J. A. Wernham

Introduction In view of the continuing depletion of natural resources, requirements for energy conservation, plant optimization and hazardous waste management, and environmental consciousness, recycling and secondary recovery of materials are being developed with increasing interest Many secondary recovery processes are being developed that apply mineral processing technology. Gravity separation, magnetic separation and flotation have all emerged as explicit methods for recovering residual values from various process streams and hazardous constituents from waste streams. Recently, a technique for concentrating metallics has been successfully reintroduced. The concept of the alternating magnetic field eddy-current separator was developed over a century ago using rudimentary electromagnets (Patent 400317 issued to Thomas Edison on March 26, 1889). Widespread acceptance was, however, hindered by high costs, marginal results and poor economic incentives for secondary recovery. With the recent increased interest in secondary recovery and the development of high-energy rare earth permanent magnets, the eddy-current separator has now gained prominent acceptance. The separation forces imparted by an eddy current separator are the function of the magnetic field intensity and the alternating frequency of the magnetic field. The evolution of permanent magnets has provided a cost effective alternative for the generation of high-intensity magnetic fields. High-energy rare earth permanent magnets have substantially reduced the capital and operating costs over the electromagnetic circuits employed in antecedent eddy-current separators. Specifically, in recent years, the strength of permanent magnets has increased several fold with neodymium-boron-iron rare earth magnets now providing an energy product of 35 million gauss-oersted. Figure 1 shows the evolution in the strength of permanent magnets. The development of these rare earth magnets has led to the design of circuits possessing a magnetic force an order of magnitude greater than that of conventional permanent magnetic circuits. The eddy-current separator has been successfully applied in several metal sorting and recovery operations. Most common is the sorting of metal from shredded automobile scrap and municipal waste. With the advent of high-frequency, high-intensity magnetic fields, the separator has advanced to the point where it has direct application in the beneficiation of fine sized metals. Relatively fine sized (-1/4 in.) metal bearing slags and spent foundry casting sands as well as precious metal hearing electronic scrap demonstrate excellent metallurgical response to the eddy-current separator, and applications have progressed to finer materials and more selective separations. Theory Electrical currents are induced in all conductors when exposed to an alternating magnetic field. The induced current generates a magnetic field in the conductor that opposes that of the alternating magnetic field. Figure 2, is a schematic illustration of generated eddy currents. In this particular example, the alternating magnetic field is produced by a series of permanent magnets mounted on the circumference of a rotor. The permanent magnets have alternating polarity. As the rotor revolves, an alternating magnetic field is produced, and the rate of revolution determines the frequency of the alternating magnetic field. When a conductor, such as a metallic disc in the illustration, is placed in the alternating magnetic field, a closed loop current flow occurs. The current loop in the conductor produces a magnetic field that is a mirror image of the alternating magnetic field. At any point in time, the induced magnetic field in the conductor directly opposes the alternating magnetic field. This opposition of magnetic fields produces an instantaneous repulsion in the conductor. The conductor is consequently repelled from the rotor. The alternating magnetic field has no effect on nonmetallic materials as they pass through the magnetic field and discharge the rotor in a natural trajectory. [ ]

Jan 1, 1992

By Dr. Richard F. Coon, James D. Mavis

Risks and abatements associated with preliminary reconnaissance, plugging and filling, and maintenance of perched mine water pool are examined. This case history showed that the initial appeal of portal plugging was replaced by concern over potential environmental hazards when details of implementation were investigated.

Jan 1, 1992

By Heikki Tuovinen

The total utilization of raw materials and energy is the most important criterion when planning. industrial processes. The main goal is clearly to use the raw materials and energy as effectively as possible in order to make the desired products directly in the primary process itself', or to recycle unused materials and energy either as such, or after cleaning back into the process. However, few industrial processes are so straightforward. Most processes generate by-streams of materials and energy, which cannot be recycled directly and it is namely these by-streams which tend to remain as wastes. These by-streams are slags, dusts, vaporized metals, liquids, slurries, sludges, gases etc. Most base metal processes produce all these by-products. Waste water and gas emission controls and regulations are tightening all the time, so new processes must be developed to keep pace with these requirements. These processes generate more solid wastes, which must be utilized or at least processed into a harmless form landfilling. Municipal and hazardous wastes also contain valuable materials and energy, which must be used to minimize landfilling. The development of processes for these purposes places even greater demands on research and development. The same principles and methods developed for mining, ore dressing and metal refining processes can also be adapted for research and development work on processes for waste minimization. However, the problems encountered are much more complicated and less familiar, demanding more versatile and accurate tools and equipment. This paper presents principles, examples and some references of R & D work on processes for waste minimization.

Jan 1, 1992

By Richard P. Roberts

This paper will discuss the methods for the cooling of aluminum melting furnace? dross .and their impact on the environment. Also discussed will be a case history of an AROS Dross Processor installation, which is designed to maximize the recovery of metal content of the dross in a manner which is not only environmentally cleaner, but which also prepares the output in such a way as to facilitate downstream processes. Handling of the discharged material will be discussed in regards to the recycling of the preserved metal content and deposition of the unusable-materials.

Jan 1, 1992

By Doon Gibbs

In this talk, we review highlights of x-ray magnetic scattering studies performed during the last decade, concentrating at the beginning on experiments on the rare earth metal holmium.(1-4) Besides intrinsic interest in the x-ray scattering cross-section and its description, studies of this type are motivated by the possibility that new structural and magnetic properties of rare earth metals might be revealed, and that new techniques may thereby be developed. As a result, interest in x-ray magnetic scattering experiments. has grown rapidly during the last 10 years particularly, with the regular application of synchrotron radiation techniques- Magnetic scattering experiments have by now been performed at most of the x-ray synchrotrons around the world. In addition, insertion .device beamlines dedicated to x-ray magnetic scattering experiments are planned at each of the next-generation storage rings presently under construction in the United States (APS), Europe (ESRF), and Japan (SPRING-8). Generally, the results of x-ray magnetic scattering experiments may be analyzed within two regimes of the incident x-ray energy, namely, in the limit of high x-ray energies, when the incident x-ray energy lies above the excitation energy of any absorption edge, and at resonance, when the incident energy lies near an absorption edge. In the high energy limit, the amplitude for x-ray magnetic scattering has the simple form [L(Q)?A + S(Q)?B](5-7) Here, L(Q) and S(Q) refer to the Fourier 'transforms of the atomic orbital and spin magnetization densities, respectively, and the vectors A and B depend on the incident and scattered wavevectors and on the: incident and scattered polarization vectors. 7) Because the vectors A and B are not identical, the polarization dependence of the orbital contribution to the magnetic cross-section differs from that of the spin contribution. This leads to the possibility that the orbital and spin magnetization densities maybe distinguished, in x-ray scattering experiments. The same distinction is not directly possible by neutron diffraction techniques (in dipole approximation, where the polarization dependence of the orbital contribution is identical to that of the spin contribution), and is important to a fundamental understanding of the electronic structure of magnetic materials. A particular

Jan 1, 1992

By E. Manev

Thin aqueous equilibrium film studies and surface tension measurements on a mixed surfactant system consisting of polyethylene oxide (a model frother) and potassium ethyl xanthate (a model collector) enable the interaction between the two surfactants at the air/solution interface to be elucidated. For the film containing the non-ionic frother, the interface was charged and addition of low concentrations of xanthate acted as a common electrolyte and reduced the thickness of the film inducing rupture. However, at high xanthate collector concentrations, the negative charge xanthate was found to interact with the non-ionic and caused a build-up of negative charge at the air/solution. Higher frother concentrations were necessary to produce non-rupturing thin films upon increasing the xanthate concentration.

Jan 1, 1992

By M. Zanotto

[ ] A period of heavy rains caused the river Adda to flood parts of the Valtellina, one of the Alpine valleys of Northern Italy. The exceptionally high waters put under considerable strain the whole system of embankments and levees controlling the river and protecting the adjacent towns and lands. In some places the water breached and washed away the embankments, submerging large tracts of cultivated land, buildings, roads and railway tracks. The town of Talamona, in the lower Valtellina, was hit particularly hard: in its proximity the river overrun and then washed away 300 m (1,000 ft) of embankment (see vicinity map, fig. 2), depositing large amounts of riverbed debris onto over 400 hectares (1,000 acres) of fertile land.

Jan 1, 1992

By G. W. Luxbacher

Acid rain legislation included in the Clean Air Act Amendments of 1990 caused a great deal of uncertainty regarding the price, source and production quantities of coal supplied to the eastern coal market. Powder River Basin and other western coals continue a rapidly accelerating migration eastward. South American coals move into the northern markets. States are proposing legislation to assist utilities in complying with the new regulations in hopes of maintaining their own coal industries. Some utilities question the long-term availability of eastern compliance coal. Major coal producers must make decisions now to assure their continuing presence in the market place. Several companies have adopted a strategy to acquire eastern compliance reserves, while others have invested in technology to compete as a low-cost producer. Legislation "Acid rain." This is a topic that was debated within the scientific, environmental and industrial communities for years. Those discussions resulted in a large outlay for the federal National Acid Precipitation Assessment Project (NAPAP), which was then ignored. Acid rain then became the subject of a "60 Minutes" broadcast that debunked the acid rain theory, supporting the NAPAP study conclusions. In the final outcome, however, acid rain was the driver for the Clean Air Act Amendments of 1990.

Jan 1, 1992

Lignite constitutes approximately 97 percent of the near-surface coal resources in Texas. The most significant bituminous resources are in the north-central and southern parts of the state. Coal reserves in Texas are estimated to be 13.7 billion tons, about three percent of U.S. coal reserves. The average thickness of coal seams mined in Texas is approximately eight feet. Texas gained primacy when its regulatory program was conditionally approved February 16, 1980; the program was fully approved June 18,1980. The state's Abandoned Mine Lands program was approved June 23,1980.

Jan 1, 1992

By D. E. Ranta, Stephen W. Thomas, Clancy J. Wendt

One of the most difficult tasks associated with placer mining is the sampling of the deposit. More placer projects have failed due to inaccurate assessment of the reserves than to any other reason. Within the realm of placers, those containing valuable minerals with a high unit value are more difficult to sample than those with larger bulk, lower unit value minerals. Some items to consider when sampling a placer deposit are as follows: A. A relatively large sample is needed for accurate valuation of the ground being tested. Placers are composed of many sizes of gravel which makes a representative sample difficult to obtain. B. When sampling placers for high unit value minerals such as gold, any error in mineral content of the sample will be magnified in the calculation of reserves. C. Values are usually erratically distributed within the gravel mass. Therefore, some placers with a more uniform value distribution may be adequately assessed with a minimum number of samples whereas a deposit with a highly erratic distribution of values may not be adequately sampled regardless of how many samples are taken. D. The investigation of a placer deposit should be made by, or be under the direction of, a person experienced in the art of placer sampling. F) During a sampling program, items that must be observed and noted in addition to the sample size and valuable mineral content should include boulder size and number, clay content, bedrock conditions, water, frozen ground, false bedrock, and any other physical characteristics that would affect mining of the deposit.

Jan 1, 1992

By Duran A, Eggers M. J

It is standard practice in geotechnical studies for mine design to drill a series of inclined oriented boreholes into the proposed pit walls. However, this investigation tool is often used without an adequate understanding of the inherent shortcomings in the method and the many potential sources of error. Of the more commonly used orientation methods in Australia the clay imprint technique is probably the most reliable. Contoured stereographic plots of oriented core data are frequently characterised by diverse pole distributions and low concentration maximums compared with line mapping data. Common sources of error producing these poor results are misinterpretation of orientation marks or imprints, inaccurate marking of the reference line, errors in the structural measurement of the defects, lack of continuity information and blind zones sub-parallel to the borehole direction which correction methods frequently do not fix. Line mapping is the preferred method of structural data collection due to the lower overall cost, availability of continuity information and higher accuracy. The projectability of field mapping data to final wall positions can be assessed with a good understanding of the regional geology and local structural patterns. Where field mapping is not possible due to a thick regolith cover, core orientation should be carried out by experienced personnel to minimise the many potential errors.A series of case studies are presented which compare oriented core with mapping and highlight the inherent problems with the technique.

Jan 1, 1992

A major problem with many items of underground equipment is that they have either been converted or adapted from surface equipment, or that they have been designed and assembled in comfortable offices and factories with adequate lighting, specialised tools, and ample space. As soon as they are in use underground in cramped spaces maintenance frequently becomes difficult, parts are awkward to change, and a whole range of accidents can happen.Similarly, ingenious operators discover a whole range of uses for which the equipment was not designed, such as using a loader bucket for a work platform, or scaling backs with it.Design modifications of equipment and removal of hazardous components that can trap limbs is expensive when the dangers are discovered in operation, sometimes posthumously, and it is not surprising that workers compensation insurance premiums are high. The cheapest place to ensure that equipment is safe is in the design office, where the operator should be considered first, rather than being added to a purpose built machine as an afterthought.

Jan 1, 1992

Rehabilitation has been very effective in the short to medium term in providing a cost effective and reliable means of containing the side effects of land disturbance. However, there is still insufficient data to critically evaluate the sucess of rehabilitation in the long term. There is an urgent need to develop objective criteria to monitor the sucess of rehabilitation. The aim of rehabilitation in Australia has traditionally been to return disturbed land to natural vegetation compatible with the surrounding area. This objective has often been accepted instinctively without adequately addressing alternatives.

Jan 1, 1992

In its April 1991 issue, MINING ENGINEERING published a salary survey form asking for information relating to engineering and management jobs in the minerals industry. 1038 of these forms were filled out and returned, most of them being received in the magazine's offices at SME headquarters before the end of June 1991. An SME volunteer took on the task of tabulating and analyzing data from the forms, but the press of other business interfered with this work, and publication has been delayed until this issue of MINING ENGINEERING. Appreciation is extended to SME members who took the time to fill out and return the salary survey forms, and our apologies go to MINING ENGINEERING'S readers for the delay in publication. Of the total number of forms received, more than 97% were from SME members. The geographic distribution of the respondents closely mirrored that of SME membership as a whole, about 50% being from the Society's Western Region, 19% from the Central Region, and 23% from the Eastern Region. About 8% were from outside the US. Average salaries for each of the four geographic areas ranged between $55,000 and $60,000, with the highest average in Eastern Region (Fig. 1). Respondents were asked to answer a number of questions formulated to determine if there are significant differences in salaries based on the type of organization for which they work. As indicated by Table 1, salary averages at mining companies do not vary markedly with the size of the company: • Large companies, defined as those having more than $1 billion in annual sales, accounted for just over 16% of the returns. Their average salary was $61,840 per year.

Jan 1, 1992

By Liu Q, Siefken T. C, Misra V. N

Investigation of the differential flotation characteristics between arsenopyrite and pyrite in a ore concentrate have been carried out on a laboratory Leeds flotation cell. Experimental results indicate that some limited separation between arsenopyrite and pyrite is possible by differential flotation under the conditions of high pH and low pulp redox potential. The best performance in this testwork was achieved by using an oxidizing agent at pH 10.7. Of the oxidizing agents tested, NaOCI gave better oxidizing effect than KMnO4. It has also been observed that the pulp redox potential depends on the pulp pH value. At high pH values a hydroxide layer is formed on the arsenopyrite surface, which has the effect of a depressant on the arsenopyrite.

Jan 1, 1992

By Art Johnston

Gas handling at Magma Copper Company's, San Manuel smelter receives process gas from a flash smelting furnace and four copper converters. The major gas handling equipment consists of four electrostatic precipitators and a sulfuric acid plant. Process vessels in gas handling are typically confined spaces. Lethal gases., mechanical and chemical hazards, and the difficulty of rescue, should an accident occur, makes this area a must in the safety plan. The presence of hazardous chemicals and explosive gases in process vessels and piping are of major concern when repairs are required. Proper job procedures are critical to prevent injury during repairs. This includes plant employees and contractors who are likely to be unfamiliar with the hazards involved. The safe operation of a gas handling operation must include the functions of operations employees on a daily basis. This includes a safe working environment and involvement. of all employees in the safety program. If an injury does occur quick medical response is critical to prevent serious injury. Medical responders must be adeqliately trained and prepared to treat the injured person without becoming victims themselves.. The methods used at Magma copper Company to deal with these safety problems are the focus of this presentation.

Jan 1, 1992

By Yukio Ishikawa

Sumitomo Metal Mining Co,. Ltd. (SMM) has been producing 22,000 t/y of electrolytic nickel at Niihama by nickel matte electrorefining process since 1970. Although the matte electrorefining is an established process and the productivity has been greatly improved in the last 20 years, SMM has intensively developed the chloride process for the nickel production since 1970's. The nickel and cobalt refining process involving solvent extraction and electrowinning from the chloride solution has been successfully developed for the treatment of the mixed sulphide in 1975. The first application of chlorine leach to the anode slime has been succeeded since 1986. Based on those technology, the matte chlorine leach electrowinning process (MCLE) has been developed as an alternation to the relatively old technology of matte electrorefining. The new process offers significant cost down and excellent quality of the product. In 1986, the feasibility of MCLE was confirmed by the test work using the integlated pilot plant. The innovation of the chlorine leach process has been undertaken by this work. The new refining process can be divided into three stages including chlorine leach stage, purification stage and electrowinning stage. More than 99 % of nickel was extracted in atmospheric chlorine leach. Although copper ion was used for electron carrier in the chlorine leach, the excess copper from the feed matte is bled off from the leach circuit by de copperizing electrolysis. The copper ion of the pregnant solution is fixed on nickel matte by the cementation reaction. The nickel matte containing copper is processed in the chlorine leach. In the purification circuit, cobalt, iron and other impurities were removed from the nickel chloride solution. The nickel chloride solution is then fed into the electrowinning cell. Based on the process established, the new plant with a capacity of 330 t/M electrolytic nickel was commissioned in order to obtain the engineering data for design of the full scale plant in 1989. The performance of the plant was fully satisfied and the new process demonstrated the potential application of modern process control.

Jan 1, 1992

By J. R. Larsen

The perlite review arrived too late to appear in the June issue. Worldwide production of perlite in 1991 was estimated to be 1.7 Mt (1.9 million st). Events in Eastern Europe and the former Soviet Union caused reporting of production, consumption and reserves from those regions to cease. The US Bureau of Mines reported data only from the US and Greece. Together, the two countries produced about 701 kt (773,000 st), down from 739 kt (815,000 st) in 1990. US production of perlite amounted to about 547 kt (603,000 st) last year. US production was supplied by 10 companies operating 11 mines in seven western states. There are 74 plants producing expanded perlite in 33 states and in Canada. All the companies engaged in mining perlite are also expanding it.

Jan 1, 1992

By Bhattacharyya AK

With increasing demand for more efficient production from the underground coal mines in the Southern Coalfields- of New South Wales, their design and operational aspects are constantly being reviewed and improved. One key area in such pursuits is the reliable design of stable and yielding pillars. The current designs of pillars based mostly on experience leads to unnecessary sterilisation of coal or strata control problems. To explore such mine design problems, computer based modelling is increasingly being applied. In the study described in this paper, the object was to determine the particular width of pillars separating three roadways in a panel at which the pillars yielded completely and their loads largely transferred to the unmined coal at the flanks of the panel. This was approached through a computer simulation of the behaviour of the strata around a panel, in which the three roadways were separated by pillars of progressively decreasing width. A computer program called FLAC based on the finite difference method was used to simulate the relevant strata behaviour in vertical sections. The appropriate in situ values of the deformability parameters relating to the coal seam, roof and floor were determined from the back analysis of some displacement measurements in such a panel. The process involved successive modelling of a vertical section through such a panel,starting with realistic values of the parameters and varying them until the measured and the modelled displacements agreed closely. Based on the results of the numerical modelling, the width of a yielding pillar for the given conditions is Suggested.

Jan 1, 1992

By Jack Eloranta

To improve control of blasting, tests were performed to assess non-electric cap accuracy. Simultaneous testing using a Velocity of Detonation Recorder (VODR), Red Lake LoCam and an Instantel DS-677 blast monitor was done. Favorable comparisons were found in the three records. This testing confirmed the accuracy of an inexpensive and expedient cap testing procedure.

Jan 1, 1992